Roll-Formed Shipping Containers with Adjustable Dimensions
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Solution Overview
Problem
Fulfillment centers face inefficiencies in packing and shipping due to the need for various sized containers, leading to waste, environmental impact, and increased processing time, especially with items of different shapes and sizes.
Innovation Solution
The development of roll-formed containers made from recyclable materials, formed around items using a system of rollers and folders to create custom-sized containers with adjustable dimensions and seals, capable of producing up to 2000 units per hour, utilizing camera and sensor assemblies for precise item dimensioning and placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If fixed-size containers are used for shipping, then container manufacturing is simplified, but packaging waste increases and packing efficiency decreases due to items of different shapes and sizes requiring fillers and oversized packaging
Solution Approach 1:
The container formation system dynamically adjusts container dimensions based on real-time measurement of items to be packaged. Rollers and folders are positioned variable to create containers of different sizes, transforming a static fixed-size container approach into a dynamic custom-size system that adapts to each item's dimensions, thereby reducing packaging waste while managing complexity through automation
Solution Approach 2:
The system changes the dimensional parameters of containers based on measured item characteristics. By varying length, width, and height parameters according to item size, the system optimizes packaging fit and reduces waste materials, while the automated parameter adjustment manages the complexity through centralized control
2Productivity
If custom-sized containers are created for each item, then packing efficiency and waste reduction improve, but processing time and system complexity increase
Solution Approach 1:
The system performs preliminary measurement of items using camera assemblies and sensor arrays before container formation begins. This advance measurement allows the container dimensions to be pre-calculated and prepared, eliminating measurement delays during the actual packaging process and improving overall packing efficiency without significant time loss
Solution Approach 2:
The container formation system operates continuously with rollers and folders working in an unbroken sequence to form containers. Items move continuously through the measurement and formation process, eliminating idle time between packaging operations and maintaining high productivity while managing processing time through streamlined continuous operation
3Object-affected harmful factors
If recyclable materials are used for roll-formed containers, then environmental impact is reduced, but manufacturing cost and process complexity may increase
Solution Approach 1:
The system uses a single type of recyclable material (such as corrugated cardboard) but varies its dimensional parameters to create different container sizes. This approach maintains manufacturing simplicity by using one material type while achieving customization through parameter variation, reducing environmental impact without significantly increasing manufacturing complexity
Solution Approach 2:
The roll-formed container system uses a universal recyclable material that can be formed into multiple container configurations and sizes. This multi-functional approach allows one material type to serve all packaging needs, simplifying the manufacturing process while reducing environmental impact through material recyclability and waste elimination
Data Source
AI summary
Systems, methods, and computer-readable media are disclosed for roll-formed containers for shipping. In one embodiment, an example container for an item may include a rectangular sheet of formable material, the rectangular sheet having a first crease line, a second crease line separated from the second crease line by a distance, a first crease pattern disposed adjacent to the first crease line, and a second crease pattern disposed adjacent to the second crease line. The container may include a sealant disposed about three sides of the rectangular sheet.